VEHICLE EXTERIOR VIEW
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CBT4•6
0-3 0 CBTY4 0 VEHICLE MODELS TypeModelControl method 4.0 t CBT4Transistor chopper CBTY4 ↑ 6.0 tCBT6 ↑
FRAME NUMBER
Vehicle modelCBT4CBTY4CBT6
Punching formatCBT4-10011CBTY4-10011CBT6-10011
CBT4•6
Punching position CBTY4
Left-hand frame side plate top
Left-hand front protector frame top
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HOW TO USE THIS MANUAL EXPLANATION METHOD
1.Operating procedure
(1)Operating procedures are described using either pattern A or pattern B.
Pattern A:Each step of the operation is explained with its own illustration.
Pattern B:The entire operation is indicated by step numbers in one illustration, followed by cautions, notes, and point operations.
DISASSEMBLY•INSPECTION•REASSEMBLY
Some step numbers may be omitted in some illustrations. When a part requiring tightening
torque instruction is not indicated in the illustration, the part name is described in the illustration frame.
Disassembly Procedure
1Remove the cover. [Point 1]
2Remove the bushing. [Point 2]
3Remove the gear.
Point Operations [Point 1]
Disassembly:
Operation to be explained
Explanantion of operation point with illustration
Make match marks before removing the pump cover. [Point 2]
Inspection:
Measure the bushing inside diameter.
Inspection:Limit 19.12 mm (0.7528 in)
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Example of pattern B
Tightening torque unit T=N•m (kg•m) [ft•lbf]
1 2 3 1 4 7 6 9 5 8 5 T = 46.1 to 48.1 (470 to 490) [34.0 to 35.5]
2.How to read component figures
(1)The component figures use the illustration in the parts catalog for the vehicle model. Please refer to the catalog to check the part name.
3.Matters omitted from this manual
(1)This manual omits descriptions of the following jobs, but perform them in actual operation:
(a)Cleaning and washing of removed parts as required
(b)Visual inspection (partially described)
TERMINOLOGY
Caution:
Important matters, negligence of which may cause accidents. Be sure to observe them.
Note:
Important items, negligence of which may cause accidents, or matters in operating procedure which require special attention.
Standard: Value showing the allowable range in inspection or adjustment.
Limit: The maximum or minimum value allowed in inspection or adjustment.
ABBREVIATIONS
AbbreviationMeaningAbbreviationMeaning
ASSYAssemblySAE Society of Automotive Engineers (USA)
LHLeft handSSTSpecial service tool L/LessSTDStandard
OPTOptionT=Tightening torque
O/SOversize TNumber of teeth ( T)
PSPower steeringU/SUndersize
RHRight handW/With
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(Example) 3201 Parts catalog FIG number
OPERATING TIPS
GENERAL INSTRUCTIONS
1.Safe operation
(1)After jacking up, always support with wooden blocks or rigid stands.
(2)When hoisting the vehicle or its heavy component, use wire rope(s) with a sufficient reserve in load capacity.
(3)Always disconnect the battery plug before the inspection or servicing of electrical parts.
2.Skillful operation
(1)Prepare the tools, necessary measuring instruments (circuit tester, megohmmeter, oil pressure gauge, etc.) and SSTs before starting operation.
(2)Check the cable color and wiring state before disconnecting any wiring.
(3)When overhauling functional parts, complicated sections or related mechanisms, arrange the parts neatly to prevent confusion.
(4)When disassembling and inspecting a precision part such as a control valve, use clean tools and operate in a clean location.
(5)Follow the specified procedures for disassembly, inspection and reassembly.
(6)Always replace gaskets, packings, O-rings, self-locking nuts and cotter pins with new ones each time they are disassembled.
(7)Use genuine Toyota parts for replacement.
(8)Use specified bolts and nuts and observe the specified tightening torque when reassembling. (Tighten to the medium value of the specified tightening torque range.) If no tightening torque is specified, use the value given in the "standard tightening torque table".
3.Protection of functional parts (battery operated vehicles)
(1)Before connecting the battery plug after vehicle inspection or maintenance, thoroughly check each connector for any faulty or imperfect connection. Faulty or imperfect connection of connectors related to controllers, especially, may damage elements inside the controllers.
4.Defect status check
Do not start disassembly and/or replacement immediately, but first check that disassembly and/or replacement is necessary for the defect.
5.Waste fluid disposal
Always use a proper container when draining waste fluid from the vehicle. Careless discharge of oil, fuel, coolant, oil filter, battery or other harmful substance may adversely affect human health and the environment. Always collect and sort well, and ask specialized companies for appropriate disposal.
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JACK-UP POINT
Always observe the following instructions when jacking up the vehicle:
•Park the vehicle on a flat surface. Be sure to avoid an inclined or rough surface.
•Use a jack with ample capacity and jack up the vehicle at the specified jack-up point. Jacking up at any other point is dangerous.
•Always support the load of jacked-up vehicle with wooden blocks at specified points. Supporting the vehicle with the jack only is very dangerous.
•Never, under any circumstances, put any part of the body (including hands and feet) under the jacked-up vehicle.
Jack-up points
Wooden block or stand setting points
Jack-up points
Wooden block or stand setting points
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CBT4•6 CBTY4
HOISTING THE VEHICLE
When hoisting the vehicle, always observe the specified hoist attachment section and method. Never hoist by any other attachment section as it is very dangerous.
CBT4•6
CBTY4
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WIRE ROPE SUSPENSION ANGLE LIST
SAFE LOAD FOR EACH WIRE ROPE SUSPENSION ANGLE
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Unit: N (tf) [lbf] Suspension angle TensionCompression Suspension method Suspension angle TensionCompression Suspension method 0° 1.00 time 0 time90 ° 1.41 time 1.00 time 30° 1.04 time 0.27 time120° 2.00 time 1.73 time 60° 1.16 time 0.58 time Rope diameter Cutting load Single-rope suspension Two-rope suspensionFour-rope suspension 0° 0° 30° 60° 90° 0° 30° 60° 90° 6 mm (0.24 in) 21380 (2.18) [4807] 3040 (0.31) [683.6] 6080 (0.62) [1367] 5880 (0.60) [1323] 5200 (0.53) [1169] 4310 (0.44) [970] 12160 (1.24) [2734] 11770 (1.20) [2646] 10400 (1.06) [2337] 8630 (0.88) [1940] 8 mm (0.32 in) 31480 (3.21) [7078] 4410 (0.45) [992.3] 8830 (0.90) [1985] 8530 (0.87) [1918] 7650 (0.78) [1720] 6280 (0.64) [1411] 17650 (1.80) [3969] 17060 (1.74) [3937] 15300 (1.56) [3440] 12550 (1.28) [2322] 10 mm (0.4 in) 49230 (5.02) [11690] 6960 (0.71) [1565.6] 14020 (1.43) [3153] 13440 (1.37) [3021] 11770 (1.20) [2646] 9810 (1.00) [2205] 27460 (2.80) [6174] 26480 (2.70) [5954] 23540 (2.40) [5292] 19610 (2.00) [4410] 12.5 mm (0.5 in) 76880 (7.84) [17387] 10980 (1.12) [2469.5] 21570 (2.20) [4851] 21280 (2.10) [4631] 18630 (1.90) [4190] 14710 (1.50) [3308] 43150 (4.40) [9702] 41190 (4.20) [9261] 37270 (3.80) [8379] 29420 (3.00) [6615] 14 mm (0.56 in) 96400 (9.83) [21675] 13730 (1.40) [3087] 27460 (2.80) [6174] 26480 (2.70) [5954] 23540 (2.40) [5292] 18630 (1.90) [4190] 54920 (5.60) [12348] 52960 (5.40) [11907] 47070 (4.80) [10584] 37270 (3.80) [8379] 2t 1tf 2t 1.41tf 90° 2t 1.04tf 30° 2t 2tf 120° 2t 1.16tf 60°
MEMBER WEIGHTS
unit: kg (lbs)
MemberVehicle modelWeight
and drive unit ASSY W/drive motor
and RH front wheels)All
TOWING THE VEHICLE
Note the cautions below when towing the vehicle.
1.There are two towing methods:
(1)Lift the front wheels (Fig. 1)
(2)Not lift the front wheels (Fig. 2) Steering operation is necessary.
2.The traveling speed when towing must not exceed the maximum traveling speed of the vehicle.
3.Before starting towing, always set the key switch to OFF and the direction switch to the neutral position.
CBTY4:EEC
1.Disconnect the parking brake cable. (See PARKING BRAKE in Section 9 for the disconnection procedures.)
2.There are two towing methods:
(1)Lift the front wheels (Fig. 1)
(2)Not lift the front wheels (Fig. 2) Steering operation is necessary.
3.The traveling speed when towing must not exceed the maximum traveling speed of the vehicle.
4.Before starting towing, always set the key switch to OFF and the direction switch to the neutral position.
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Battery ASSYSee
Drive motor ASSY CBT4•CBTY4Approx. 27 (60) CBT6Approx. 45 (99) Rear axle
CBT4•CBTY4Approx. 96 (112) CBT6Approx. 117 (258) Front axle ASSY (W/LH
modelsApprox. 15 (33) Battery hoodCBTY4Approx. 90 (200) Vehicle weight CBT4980 (2160) CBTY4975 (2150) CBT61055 (2325)
page 1-2
Fig.1
Fig.2
ELECTRICAL PARTS INSPECTION
1.Always disconnect the battery plug before inspecting or servicing electrical parts.
2.Pay sufficient attention when handling electronic parts.
(1)Never subject electronic parts, such as computers and relays, to impact.
(2)Never expose electronic parts to high temperature or moisture.
(3)Do not touch connector terminals, as they may be deformed or damaged due to static electricity.
3.Use a circuit tester that matches the object and purpose of measurement. Analog type:This type is convenient for observing movement during operation and the operating condition. Measured value should be used for reference only.
Digital type:A fairly accurate reading is possible. However, it is difficult to observe operation or movement.
(1)Difference between results of measurement with analog and digital types
* The results of measurements using the analog type and the digital type may be different. Differences between the polarities of the analog type and the digital type are described below.
1)Analog circuit tester
Example of measurement result
Tester range: kΩ range
2)Digital circuit tester
Example of measurement result
Tester range: 2 MΩ range
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Analog type Forward Continuity 11 kΩ Reverse No continuity ∞ Forward Reverse Digital type Forward No continuity 1 Reverse Continuity 2 MΩ
STANDARD BOLT & NUT TIGHTENING TORQUES
Tightening torques for standard bolts and nuts are not indicated throughout the manual. Use the charts and table below to judge the standard tightening torque.
1.Find the class of the bolt strength in the table below and then find the bolt tightening torque in the tightening torque table.
2.The nut tightening torque can be judged from its corresponding bolt type.
BOLT STRENGTH CLASS IDENTIFICATION METHOD
Identification by bolt shapeIdentification by part No.
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Shape and classClass Hexagon head bolt Hexagon bolt (standard) Bolt with raised or etched numeral on head 4 = 4T 5 = 5T 6 = 6T 7 = 7T 8 = 8T No mark4T Hexagon flange bolt No mark4T Hexagon head bolt (standard) Bolt with two raised lines on head 5T Hexagon flange bolt Bolt with two raised lines on head 6T Hexagon head bolt (standard) Bolt with three raised lines on head 7T Hexagon head bolt (standard) Bolt with four raised lines on head 8T Welded bolt4T Stud bolt No mark 4T 2 mm groove(s) on one/both edge(s) 6T Hexagon head bolt Part No. 91611-40625 Length (mm) Nominal diameter (mm) Class Nominal diameter Length Stud bolt Part No. 92132-40614 Length (mm) Nominal diameter (mm) Class Nominal diameter Length
TIGHTENING TORQUE TABLE
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Class Nominal diameter mm Pitch mm Standard tightening torque N•mkgf•cmft•lbfN•mkgf•cmft•lbf 4T 6 8 10 12 14 16 1.0 1.25 1.25 1.25 1.5 1.5 5.4 13 25 47 75 113 55 130 260 480 760 1150 48 in•lbf 9 19 35 55 83 5.9 14 28 53 83 60 145 290 540 850 52 in•lbf 10 21 39 61 5T 6 8 10 12 14 16 1.0 1.25 1.25 1.25 1.5 1.5 6.4 16 32 59 91 137 65 160 330 600 930 1400 56 in•lbf 12 24 43 67 101 7.5 18 36 65 100 157 75 175 360 670 1050 1600 65 in•lbf 13 26 48 76 116 6T 6 8 10 12 14 16 1.0 1.25 1.25 1.25 1.5 1.5 7.8 19 38 72 110 170 80 195 400 730 1100 1750 69 in•lbf 14 29 53 80 127 8.8 21 43 79 123 191 90 215 440 810 1250 1950 78 in•lbf 16 32 59 90 141 7T 6 8 10 12 14 16 1.0 1.25 1.25 1.25 1.5 1.5 11 25 52 95 147 226 110 260 530 970 1500 2300 8 19 38 70 108 166 12 28 58 103 167 120 290 590 1050 1700 9 21 43 76 123 8T 6 8 10 12 14 16 1.0 1.25 1.25 1.25 1.5 1.5 12 29 61 108 172 265 125 300 620 1100 1750 2700 9 22 45 80 127 195 14 32 68 123 196 299 145 330 690 1250 2000 3050 9 24 50 90 145 221 Hexagon head bolt Hexagon flange bolt
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PRECOATED BOLTS
(Bolts with seal lock agent coating on threads)
1.Do not use a precoated bolt as it is in either of the following cases:
(1)After it has been removed.
(2)When it has been moved by tightness check, etc. (loosened or tightened)
Note:
For torque check, tighten the bolt to the lower limit of the allowable tightening torque range; if the bolt moves, retighten it according to the steps below.
2.How to reuse precoated bolts
(1)Wash the bolt and threaded hole.
(The threaded hole must be washed even when replacing the bolt with a new one)
(2)Completely dry the washed parts by blowing with air.
(3)Apply a specified seal lock agent to the threaded portion of the bolt.
HIGH PRESSURE HOSE FITTING TIGHTENING TORQUE
1.When connecting a high pressure hose, wipe the hose fitting and corresponding nipple contact surfaces with a clean cloth to remove foreign matter and dirt. Also check that there are no dents or other damage on the contact surfaces before installation.
2.When connecting the high pressure hose, hold the hose to align the fitting with the nipple and tighten the fitting.
3.The maximum tightening torque must not exceed twice the standard tightening torque.
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Nominal diameter of screw Tightening torque standard N•m (kgf•cm) [ft•lbf] Inside diameter of hose mm (in) StandardTightening range 7/16-20UNF25 (50) [18.1]24 to 26 (240 to 270) [17.4 to 19.5]6 (0.24) 9/16-18UNF49 (500) [36.2]47 to 52 (480 to 530) [34.7 to 38.3]9 (0.35) 3/4-16UNF59 (600) [43.4]56 to 62 (570 to 630) [41.2 to 45.6]12(0.47) 7/8-14UNF59 (600) [43.4]56 to 62 (570 to 630) [41.2 to 45.6]12 (0.47) 7/8-14UNF78 (800) [57.9]74 to 82 (740 to 840) [53.5 to 60.8]15 (0.59) 1•1/16-12UNF118 (1200) [86.8]112 to 123 (1140 to 1250) [82.5 to 90.4]19 (0.75) 1•5/16-12UNF137 (1400) [101.3]130 to 144 (1330 to 1470) [96.2 to 106.4]25 (0.98) PF1/425 (250) [18.1]24 to 26 (240 to 270) [17.4 to 19.5]6 (0.24) PF3/849 (500) [36.2]47 to 52 (480 to 530) [34.7 to 38.3]9 (0.35) PF1/259 (600) [43.4]56 to 62 (570 to 630) [41.2 to 45.6]12 (0.47) PF3/4118 (1200) [86.8]112 to 123 (1140 to 1250) [82.5 to 90.4]19 (0.75) PF1137 (1400) [101.3]130 to 144 (1330 to 1470) [96.2 to 106.4]25 (0.98)
Seal lock agent
RECOMMENDED LUBRICANT QUANTITY AND TYPES
Applicable portionTypeQuantity
1.25 Liter (0.33 US gal)
Drive unitHypoid gear oil SAE 75W-80
The oil level shall be within a range of 9 to 11 mm (0.354 to 0.433 in) from the bottom of the filler port.
The above value is for reference
Brake lineSAE J-1703, DOT-3Appropriate amount
Steering chainsMolybdenum disulfide greaseAppropriate amount
Chassis partsMP GreaseAppropriate amount
BatteryDistilled waterAppropriate amount
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